case study of introducing and applying triz to real ... · triz. tm・other ・ evaluating...

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Case Study of Introducing and Applying TRIZ to Real Projects for Obtaining Results (= Profits) (Part 2): Having Used QFD TRIZ TM, What are the Results? Case Study of Introducing and Applying TRIZ to Real Projects for Obtaining Results (= Profits) (Part 2): Having Used QFD TRIZ TM, What are the Results? Tomohiko Katagiri, Toshiaki Tsuchisawa, and Shuichi Hosaka (Koganei Co., Ltd.) English translation: Toru Nakagawa (Osaka Gakuin Univ.) S-01

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Page 1: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

Case Study of Introducing and Applying TRIZ to Real Projects

for Obtaining Results (= Profits) (Part 2): Having Used QFD → TRIZ → TM, What are the Results?

Case Study of Introducing and Applying TRIZ to Real Projects

for Obtaining Results (= Profits) (Part 2): Having Used QFD → TRIZ → TM, What are the Results?

Tomohiko Katagiri, Toshiaki Tsuchisawa, and Shuichi Hosaka (Koganei Co., Ltd.)

English translation: Toru Nakagawa (Osaka Gakuin Univ.)

S-01

Page 2: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

Mind MapⓇ

S-02

Contents

Page 3: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-03

●●

Name Name ::

Koganei CorporationKoganei Corporation

●●

Established: Feb. 7, 1934 Established: Feb. 7, 1934

●●

Capital: 640 M yen Capital: 640 M yen

●●

Employees: 750 Employees: 750

●●

Sales: 22.9 B yen (2007 FY) Sales: 22.9 B yen (2007 FY)

Business areas Business areas ::

●●

Aeropneumatic equipments and Aeropneumatic equipments and

related products: manufacturing & salesrelated products: manufacturing & sales

●●

Fluororesin products: manufacturing & salesFluororesin products: manufacturing & sales

●●

Integrated lubrication systems: manufacturing Integrated lubrication systems: manufacturing

●●

Electrostatic equipment, electrical equipment, fluid Electrostatic equipment, electrical equipment, fluid

control equipment, etc.: control equipment, etc.: manufacturing & salesmanufacturing & sales

http://www.koganei.co.jp/en/http://www.koganei.co.jp/en/

Company ProfileKomagane Plant

(Komagane, Nagano)

Tokyo Office(Koganei, Tokyo)

Page 4: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-04

① Product Line Out

300,000 types

Air cylindersAir valves

Regulators, Filters

Joints, speed controllers

Vacuum devices & pads

Electric actuators

Static electricity removing unit

Fluororesin equipments

Constant delivery pump

Education Kits, Books

Clean system equipments

Fluid control equipments

Page 5: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

① Solenoid Valves

S-05

Solenoid Valves 47 product series

Sales: about □.□ B yenEngineers: □□

Page 6: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-06

② Introduction: Establishing "Absolute Strength"

1. Recognize the real essence of customers' requirements and meet with customers' satisfaction

2. Generating unique solutions

3. Minimizing the risks for new unique solutions

QFD

TRIZ

TM・other

Evaluating customers' requirements with Kano Method.・

Planning the products which surely sell well. ・

Sharing information and language among divisions and customers.

Unrivaled competitiveness and no compromised solutions・

Achieving goal requirements without compromise・

Communication language among engineers

Preventive verification for new technologies and solutions ・

Reducing the required R&D period ・

Accumulating design know-how and sharing knowledge

Continually supply differentiated products which provide our customers with profits. ・・--> 3 Schemes for achieving the goal.

【Our Goal】・・・Establishing "Absolute Strength"

Page 7: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-07

② Introduction: Achieving "Results = Profits"

'We learned much, thanks.'

'We would like to use the method in future product development.'

'We have filed a number of patents.'

'We have evaluated the impact as xxx Million yen.'

Conventional ways

Changes in business

environments

Drastic changes --> Needs the results quickly

Higher risks in new product development --> new products with less risks

Changing employment styles --> 'Outsourcing and temporary employment in place of educating ...'

'Performance and goal management' --> Avoiding high risks

Market saturation --> Sales saturation --> sense of stagnation

Changes in engineers

Hence, we ...

Page 8: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-08

② Introduction: Our Strategy

Not only TRIZ but also QFD and TM (Taguchi Method): Apply to the whole process of R&D. --> Optimize as a whole.

Have applied to 3 real on-going projects:

Training schedule is synchronized with the project development. 2 projects: development of valves; 1 project: thermal refining equipment

Related divisions, related tools and methods:

Reorganized and implemented in synchronous to the projects.

The new products should have Results (= Profits) in 3 years from the start of the projects.

==> Verify the effectiveness.

Requested the consulting by one instructor all the way through QFD -> TRIZ -> TM -> Results.

A team of common fate and work for the same target.

Page 9: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-09

② Introduction: Training & projects together

Start

QFD Overview 1DQFD Practice 3D

TRIZ Overview 3DTRIZ Practice 7D

TRIZ Short 3D

TM Practice 8D

Tolerance Analysis Intro.

Product Planning

Part Development

Design Design verification

Decision of production

Train-

ings

Project (Valve B)

Mass-Pro. prep.Verification

Related

tools/

skills

2004:TOC/ DBR/ TA/ TP2005:TOC/ CCPM

TM Overview 1D

TA ApplicationTA practice

FMEA

Follow-up consulting

~ 2006 2007 200810 4 10 4 10

3D-CAD .... Increase the installation step-by stepCAE ........... Increased the installation step-by-step

Fiscal Year/Month

Sales prep.

7

20094

Sales

Page 10: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-10

③ QFD: Concepts of Products which surely sell well

Development Div.

Quality planning

Weights of Customer needs

Quality design

Needs-Quality Deployment

Quality-Function Deployment Weights of Quality requirementQuality parameters

Marketing Strategy Targets

Customer claim DBSpecial inquiry DBQuality information DBInquiry answers Interviews

Sales divisionQuality Div. Manufacturing Div.

Go ahead to TRIZ and TM

CustomerApplications

Quality requirement

Quality require-ment

Page 11: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-11

③ QFD: Problems in Practice

Voice of Customers

(20,000voices)

Different Customers・

Purpose of use・

Functions/ Performance

Business area

Different situations・

Competitive proposal・

Reasons for unacceptance

Marketing decisions

Different marketing・

Customers・

Regions ・

Industries

Higher performance than competitors

Higher quality

Plenty of variations

• And yet 【Lower price by 30 % than competitors】

• Difficult to focus the target customers

• Difficult to decide the priorities• Difficult to make the well-focused

specifications

• Unfocused products・

Abstract & vague target

customers・

Specifications without clear focus

QFD: Problems in constructing the Quality Table

Page 12: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-12

③ QFD: Application - Quality Deployment

PurposeUsage, Process, Equipments

Object

使用電圧範囲が広い

消費電力が少ない

サー

ジが出ない

クリー

ン度が高い

サイズが小さい

作動音が静か

水、

水蒸気に強い

ホコリに強い

量の個体差が少ない

オゾンに強い

動の信頼性が高い

RoHS

PL

容器搬送 ペットボトル 〇 〇 ◎ b c a b 12電子部品 〇 ◎ 〇 ◎ a b c a 14

〇 ◎ 〇 ◎ b c c b 8chip part 〇 ◎ ◎ ★ ◎ ★ ◎ ◎ ★ ◎ ★ a a a a 20

米粒 〇 ★ ★ ◎ ◎ ★ 〇 a a b a 18お茶葉 〇 ★ ★ ◎ ◎ ◎ ◎ 〇 a a b a 18バリ 〇 ◎ 〇 〇 ◎ 〇 〇 〇 〇 b a c b 12

切削油 〇 ◎ 〇 〇 ◎ ◎ 〇 〇 〇 a b a b 16除電イオナイザ 静電気 〇 ◎ 〇 ◎ ★ a b a a 18

冷却 熱 〇 ◎ 〇 c b a c 10圧力制御 吸着搬送 エジェクタ 〇 ◎ 〇 ★ ◎ ★ ◎ ★ ◎ ★ a a a a 20

真空包装 袋 〇 ◎ 〇 ◎ ◎ 〇 b b a b 14〇 ◎ 〇 〇 ◎ ◎ b b a b 14

General 13 30 13 20 24 20 18 0 7 8 9 18 17 147 15 7 20 11 20 12 0 7 8 9 18 13 14

C A C A B A A C B C A B A

Customer quality requirement

Extracting a bad

Market EvaluationFunctionality Needs (usage) of customers

パーツフィーダー

Stability

Brow off

空気搬送(送る)

Customer quality requirement Evaluated importance

制御 basic

Target market

空気を抜く

Quic

k start

Quic

k stop

small variation

volume of use

importance

areas of useextensibility attractiveness

Page 13: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-13

形状寸法

1次 2次 3次

作動電圧

サー

ジ回路

駆動回路

起動電流

定常電流

基板材質

パター

ン基準

耐電圧基準

配線形態

通電表示

コイル発熱量

インダクタンス

コイル断面積

巻数

電気抵抗

巻線絶縁種類

コイルモー

ルド

到達吸引力

パー

ミアンス

飽和磁束密度

非透磁率

保磁力

渦電流

吸引ギャッ

ONギャッ

可動子質量

バネ押付力

受圧力

開口面積

受圧面積

シー

ト面圧

弁ストロー

弁座平面度

弁座耐摩耗性

弁座変形量

ゴム材質

横弾性係数

引っ

張り強さ

反発弾性

圧縮永久ひずみ

耐摩耗性

使用温度範囲

耐油性

耐候性

潤滑油

本体材質

本体肉厚

ばね材質

ON緩衝性能

OFF緩衝性能

手動ボタン

流路構成

フィ

ルター

機能

配管種類

配管方向

取付方法

バルブ幅

バルブ高さ

質量

マフラー

機能

材料表示

形式ラベル

ロッ

トトレー

保証期間

修理期間

故障間隔

カタログ

形式記号

技術資料

技術サポー

MF機能

MF形状

1 2 3 4 5

レベルアッ

プ項目

目標仕様】

使用電圧範囲が広い ◎ ◎ ◎ ◎ 〇 ◎ 11 C

消費電力が少ない ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ 〇 ◎ ◎ ◎ ◎ 24 A ★ SC MKF ★ 4W→2W

サージが出ない 〇 ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ 10 C SC MKF

高圧で使える ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ 0 SC MF

たくさん流せる ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ 〇 21 A ★ SC MKF ★ 2.0→3.0

低圧時に大流量 ◎ ◎ ◎ ◎ ◎ ◎ ◎ 〇 6 ★ SC MKF ★ 2.0→4.0真空の流量特性が良い ◎ ◎ ◎ ◎ ◎ ◎ ◎ 〇 10 C ★ SC MKF ★ 2.0→4.0適用流体種類が多い ◎ ◎ ◎ ◎ 1 ◎立ち上りが早い ◎ ◎ ◎ ◎ ◎ ★ ◎ ★ ★ ★ ★ ★ ★ ◎ ◎ ◎ ◎ ◎ ◎ att 30 A 〇 ◎ ★ MKF ★ SC★ 1ms(MAX)内部圧力降下が少ない ◎ ◎ ◎ 0

クリーン度が高い ◎ 〇 ◎ ◎ ◎ ◎ ◎ ◎ 〇 ◎ att 16 B 〇 ◎ SC MKF ★ 完全禁油切れが良い ◎ ◎ ◎ ◎ ◎ ★ ◎ ★ ◎ ◎ ★ ★ ★ ★ ◎ ◎ ◎ 〇 ◎ att 30 A 〇 ◎ ★ MKF ★ SC★ 1ms(MAX)漏れが少ない ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ att 18 B ◎ ★ SC MKF ★ 0.2以下

質量が軽い ◎ ◎ ◎ ◎ ◎ ◎ 6 F MK ★ SC 同等以下サイズが小さい ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ att 21 A ★ F M K ★ SC 同等以下作動音が静か ◎ ◎ ◎ ◎ ◎ 0

空気音が静か ◎ ◎ 4水、水蒸気に強い ◎ ◎ ◎ ◎ ◎ ◎ ◎ 11 C 〇 ★ MK SCF ★ IP67

ホコリに強い ◎ 17 B 〇 ★ MK SCF ★ IP67高温に強い ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ 7 〇 SC MKF ★

低温に強い ◎ ◎ ◎ 4

振動に強い ◎ ◎ ◎ ◎ 10 C流量の個体差が少ない ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ att 12 C ★ SCMF K ★ ±10%応答の個体差が少ない ◎ ◎ ◎ ◎ ◎ 〇 〇 ◎ ◎ ◎ ◎ ◎ ◎ ◎ att 26 A ◎ ★ CMK SF★ ±10%

サージに強い ◎ ◎ 〇 ◎ ◎ com 18 B 〇異物混入に強い ◎ 0 ◎オゾンに強い ◎ ◎ ◎ ◎ ◎ ◎ ◎ com 18 B ◎ドレンに強い ◎ ◎ ◎ ◎ ◎ ◎ 〇 7内部が腐食しにくい ◎ ◎ ◎ ◎ ◎ com 15 B

作動の信頼性が高い ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ 〇 att 22 A ◎ ★ ★ 作動確認作動回数が多い ◎ ◎ ◎ ◎ ◎ att 28 A ◎ ◎ ★ MKF SC ★ 30億回長期連続通電できる ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ att 11 C ◎ SC MF K ★ 連続通電可

保障期間が長い 〇 ◎ com 3入手が早い ◎ com 3何処でも入手できる ◎ com 3

ロットがトレースできる ◎ att 0原因調査が早い ◎ com 0簡単に選定できる ◎ ◎ com 11 C

高密度設置が出来る ◎ ◎ ◎ ◎ ◎ com 11 C設置場所を選ばない ◎ ◎ 〇 ◎ ◎ ◎ ◎ ◎ ◎ ◎ com 11 C

設置作業が簡単 ◎ 〇 〇 ◎ ◎ com 11 C配線作業が簡単 ◎ ◎ com 11 C配管作業が簡単 ◎ ◎ ◎ com 11 C

作動確認が簡単にできる ◎ ◎ com 11 C手動操作が簡単にできる ◎ com 11 C形式確認が簡単にできる ◎ ◎ ◎ ◎ ◎ com 11 C

交換時期がわかりやすい ◎ ◎ ◎ com 11 C不具合箇所が見つけやすい 〇 ◎ com 11 C

入手性が良い 〇 ◎ ◎ ◎ com 11 Cバルブ交換が簡単にできる ◎ ◎ ◎ com 11 C使用材料が解りやすい ◎ ◎ ◎ ◎ com 11 C

含有有害物質が少ない ◎ ◎ ◎ com 11 C素材がリサイクルできる ◎ ◎ com 11 CCO2排出量が少ない com 11 C

空気消費量を削減できる ★ att 55 A ★ ★ 消費量半減3ポートと混載できる5ポートと混載できるRoHS comUL 429 ◎ ◎ ◎ ◎VDE 0580 ◎ ◎ ◎

PL ◎

10 8 33 16 16 2 4 5 4 2 7 18 11 17 13 1 13 19 20 18 12 6 9 11 11 8 15 7 8 17 4 14 5 12 4 16 9 5 4 16 8 5 5 4 10 16 1 9 8 7 2 4 2 3 4 2 5 5 1 1 0 4 2 5 1 1 0 3 3 3 3 8 3

5

4

3

2

1

F KF SC ★ SCK★

★ K★

過去の不良項目

●●●SC

基板温度上昇はんだクラック

・ウレタンシート接着(仕様別最適シート材質を選択)

・本体透明樹脂(作動確認・寿命判断)

新技術・新構造・新機構(太字:業界初 細字:KOG初)

ボトルネック技術

★ ★ ★ SC

SCM

・マルチオリフィス構造・弁座高さ調節機構・板バネ支持無摺動構造

顧客重要度

重 要 度

機能性

制御

基本機能

その他

安心

耐外部環境性

安定性

耐久性

保証

お手軽

設置性

メンテ性

その他

環境負荷

MF

法令・規制要求事項

制御回路

機能特性 外観特性 競合製品比較

品質企画

セー

ルス

ポイント

その他

品質の性質

安心材料特性

★ ★

MF資料配管流路 環境

要望項目

クレー

コイル特性 磁気回路特性 弁座特性 弁体特性

●M

S SFC FK★

MFFSC●

・磁気回路最適設計・磁性材料

・弁座形状最適設計・弁座精密成形(金型)技術

・硬質ウレタン加工技術・弾性体解析技術

・構造解析

SC● ●

MMFK MKF MKF MKF

競合製品技術水準比較

・Vcc供給駆動(3線式)・可変PWM制御・パルスジェネレータ機能

・パラレルコイル・並列/直列切換・中空コイル(検討)・常温エポキシモール

・馬蹄形フレーム構造・方向性珪素鋼板・カットコア製法・粉末冶金可動子

K KF KF

M SCM目標設定

SMSCMKF★ CK●

C●

ガスケット締め代不足ねじの緩み

顧客要求品質

顧客重要度評価

重点項目 コイル発熱・断線温度上昇→作動不良

ギャップのバラツキ→作動不良

面精度不良摩耗・弁座の変形

摩耗・圧縮永久ひずみ膨潤・変形

機種数

・インダクタンス解析・コイルモールド・電磁解析

DR必須部門

営業・代理店・Web・サポートロットトレース客先使用誤り・異常なし

・インラインフィルター内臓

異物噛み込み

・回路設計技術

★:新製品の目標S:SMC 2PortC:CKD 2PortM:MAC 3PortK:KKS 3PortF:FESTO 3Port

●:KOG現製品(HV160)★:新製品の目標S:SMC 2PortC:CKD 2PortM:MAC 3PortK:KKS 3Port

③ QFD: Quality - Function Deployment

Solving contradiction

with TRIZ

Optimal conditions

with TM

Solving contradiction

with TRIZ Optimal conditions

with TM

Cost reductionwith TRIZ

Page 14: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-14

③ QFD: Effects of Introduction before the TRIZ Process

While constructing the QFD tables, we can see we should sell what quality, to whom, and in which way.

All the members of sales and development divisions decide together clear and convincing target specifications.

We realize the importance and priorities of technical problems we must solve from now on.

We must solve these problems by all means, even though no techniques and means are known so far. --> High motivation

Go ahead to TRIZ and TM

Page 15: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-15

④ TRIZ

Technical problems to be solved

Technical problem (Target specification)

New solenoid structure, having large flow rate, high speed response, and yet low power consumption, and long duration

(==> New engine, having high power, high speed response, and yet low fuel cost, and long duration.)

New main valve structure which can extract max. features of the new solenoid. (==> New power train system which can extract max. features of the new engine.)

magnet circuit(Engine)

Valve structure(power train system)

Electric power (Gasoline)

Power

Fluid control (motion)

Function of Electromagnetic valve (In case of application to car engines)

Inlet Outlet

Page 16: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-16

④ TRIZ: New solenoid structure

High-speed response

Low power consumption

Prediction, Principles,

Effects, Trimming

Large flow rate

Long duration

Target specification Function-Attribute Analysis

TRIZTM (Taguchi Method)

Optimized design

Page 17: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-17

④ TRIZ: New Solenoid structure

Single cylinder --> Double cylinders

Single layer --> 22 layers

Extremely-short stroke

Square frame "コ" --> "U" frame

"I" shape armature --> flat plate armature

Directional electro-magnetic steel plates

no sliding motion

Page 18: Case Study of Introducing and Applying TRIZ to Real ... · TRIZ. TM・other ・ Evaluating customers' requirements with Kano Method. ・ Planning the products which surely sell well

S-18

⑤ TM: Deployment to Taguchi Method (TM)

Technical Problem (Target specification)

New solenoid structure, having large flow rate, high speed response, and yet low power consumption, and long duration

(==> New engine, having high power, high speed response, and yet low fuel cost, and long duration.)

New Horizon Unknown structure for usNo experiences and know-how available or effectiveNo expert existing Long period and high cost foreseen in the prototyping So many parameters to verify in the design

Target task: Optimal design of the new solenoid structure Want to find the optimal conditions as quickly as possible ...Verify the stability in the mass production

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1. Analysis of the theme

Function-Attribute Analysis

Task: Optimal design of the new solenoid structure

2. Identify the target function

Function-attribute analysis --> Fishbone diagram

3. Identify the ideal function

y = βM , where y: effective work, M: power consumption

4. Identify various factors

error factors: accuracy in size, increasing temperaturecontrol factors: design parameters, L18 orthogonal matrix

CAE: Simulation with Electromagnetic analysis software

⑤ TM: Deployment to Taguchi Method (TM)

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⑥ Results: New Products we developed

High-speed response 2-port valve

【Industry top performance】

【Comparison with our conventional products】

High-speed response less than 1/2 in response time

Compact and large flow rate

over 3 times in flow rate

Low power consumption less than 1/2 in electric power consumption

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⑥ Results: Application examples

QFD: Driving circuit

QFD: Interface specification

TRIZ: Coil structure

QFD: Inner specification

TRIZ: Magnet circuit

TM: Magnet optimization

TRIZ: Core structure

TRIZ: Trimming

TRIZ: Main valve structure

TRIZ: Adjusting mechanism

TRIZ: Trimming

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⑥ Results: Usage example of the product (1)

NGNo-good items

OK

OK

OK

OK

OK

NG

Judging

Output pulse pressure

Input pulse voltage

Selection process

High-speed response + Large flow rate --> Shorter tact time, Better selection accuracy

befo

re s

elec

tion

good

item

s

High-speed response 2-port valve

Compressed air Nozzle

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⑥ Results: Usage example of the product (2)

Blowing process

High-speed response + pulse drive --> Better blowing effects, reduced air consumption

Nozzle Compressed air

Output pulse pressure

Input pulse voltage

【ref】 【ref】 【ref】Electricity Saving Reduction

(kW/h) power /yr CO2/yrmonthly yearly ¥16/kWh (kWh) (ton)

0.8 0.5 0.4 1.69 4.2 338 4,052 0.26 253 0.71.1 1 0.4 3.38 8.4 675 8,104 0.53 507 1.41.6 2 0.4 6.75 16.9 1,351 16,209 1.06 1,013 2.82.0 3 0.4 10.13 25.3 2,026 24,313 1.58 1,520 4.3

Nozzleφ

(mm)Area

(mm^2)

Pressure(MPa)

Flow rate(m^3/h)

8 hr/d, 20d/mo working1/2 pulsing

Electricity cost savingCost of Comp. air

(¥/h)¥2.5/m3

High-speed response 2-port valve

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⑦ Conclusion: Product extension in future

Sales situations

Extension of the product series

Apr. 2009: Marketing research to a limited range of customers May 2009: Delivery of sample products for customer evaluationJul. 2009: Sales to the open market Trade inquiries much larger in volume than the expected ones. --> Short in supply!

New variants installing with pulse blowing circuit.-- Less air usageNew variants installing with power saving circuit -- Less energy consumptionSuper high-speed response type -- Challenging ever.

Development of applications

New applications with effective use of high-speed response.New aeropneumatic devices with effective use of high-speed response.New devices with effective use of high-speed response solenoid technology

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⑦ Conclusion: Human resource development plan

Target Customers (to whom)

Non-technological problems

Marketing strategy (how) Customer quality requirement (what)

Effective use of existing know-howNew solutions

Clarify technological problems

Product design, Manufacturing design

Products to the market

TOC/TP (Thinking process)

Market mix.

Quality problems, claims Cost increase, Design changes

Fire-fighting actions, (Shortage in man power)

similarity with competitors Weakening of IP Dispersion of knowledge

Mismatching with the customer requirements

Prolonged development, Delay to the market

QFD (Quality Function Deployment)

TRIZ (Theory of Inventive Problem Solving)

TM: Taguchi Method (Quality Engineering)

3D CAD, FEM Analysis & design tools

TOC/CCPM (Project Management)

TOC/TA (Throughput Accounting)

KM (Knowledge management)

Training program of engineers

Engineering information DB

Design & computation documents

Tolerance Analysis

FMEA

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⑦ Conclusion: Aspects of Management

1. Raise the sense of crisis

8 Steps for Innovation (John P. Cotter)

2. Build the innovation team

4. Familiarize the vision for innovation

3. Create the vision and strategy

5. Encourage members voluntary actions

6. Achieve short-term success

7. Promote further innovation

8. Establish the new ways

Kano method

Mission of wild pikes

QFD: Needs-quality deployment

QFD: Quality-function deployment

TRIZ and TM

Sales of new products --> Profits

Applying to other products

Install in the production system

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⑦ Conclusion: Reference

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For introducing TRIZ to us: Mr. Masayasu Fujimori (PronoHearts)

For encouraging us to install: Mr. Mamoru Zenko (IDEA)

For instructing us in the team: Mr. Hajime Kasai (IDEA)

For many surprise chain: All the members involved

For introducing TRIZ to us: Mr. Masayasu Fujimori (PronoHearts)

For encouraging us to install: Mr. Mamoru Zenko (IDEA)

For instructing us in the team: Mr. Hajime Kasai (IDEA)

For many surprise chain: All the members involved

Thank you for your attentionThank you for your attention

AcknowledgementAcknowledgement

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